Pre-Stressed Textile-Reinforced Composite to Reduce Seam Failure
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Solution Overview
Problem
Conventional fiber-reinforced composite materials lack the necessary strength, durability, and toughness for long-term use in load-carrying structures, particularly due to their brittleness and susceptibility to failure at seams and joints, which are introduced by the assembly of multiple pieces.
Innovation Solution
The method involves pre-stressing a textile reinforcement preform by applying tension, followed by introducing a polymeric precursor and curing it, which results in a composite article with a pre-stressed, seamless knitted reinforcement structure and a cured or consolidated polymer, allowing for controlled pre-stress levels and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fiber-reinforced composite materials are used, then lightweight structure is achieved, but strength and durability are insufficient due to brittleness and seam failure
Solution Approach 1:
The textile reinforcement preform is pre-stressed by applying tension before introducing the polymeric precursor and curing it. This preliminary action of pre-stressing the reinforcement structure before final assembly eliminates seams and joints that would otherwise be weak points, thereby improving both strength and durability of the composite material
Solution Approach 2:
The method combines the textile reinforcement preform with polymeric precursor in a seamless manner through pre-stressing and curing, creating a unitary composite structure without seams or joints. This merging of materials and processes eliminates the weak portions that would otherwise compromise durability
2Shape
If multiple pieces of composite material are assembled to form complex three-dimensional structures, then structural complexity is achieved, but seams and joints are introduced that reduce reliability
Solution Approach 1:
The textile reinforcement preform is pre-stressed and shaped into the desired complex three-dimensional configuration before the polymeric precursor is introduced and cured. This preliminary forming action allows the creation of complex shapes as a single unitary structure, eliminating the need to assemble multiple pieces and avoiding seams and joints
Solution Approach 2:
The textile reinforcement preform can be designed with distinct knitted regions having different pre-stress levels, allowing different portions of the structure to have different mechanical properties. This segmentation within the preform enables complex three-dimensional shaping while maintaining a seamless unitary structure
3Strength
If unidirectional fibers are used for reinforcement, then structural performance is improved, but manufacturing becomes expensive and cumbersome requiring specialized equipment and skilled labor
Solution Approach 1:
The invention changes the form factor of the reinforcement from unidirectional fibers to a textile reinforcement preform that can be knitted or woven into complex three-dimensional structures. This parameter change in the reinforcement architecture maintains structural performance while dramatically simplifying manufacturing, as the preform can be handled as a single piece requiring no specialized laying up equipment or skilled labor
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the mechanical performance of composite materials by increasing modulus, strength, durability, and fatigue life, reducing the likelihood of failure at seams and joints, and enabling the formation of complex, unitary three-dimensional structures with improved structural integrity.
Implementation Method 1
A polymeric precursor may then be cured
Implementation Method 2
pre-stressing a textile reinforcement preform by applying tension
Implementation Method 3
The polymeric precursor may be consolidated by applying heat, pressure, or heat and pressure
Implementation Method 4
The polymeric precursor may be consolidated by applying heat, pressure, or heat and pressure
Data Source
AI summary
Methods to increase structural performance, strength, and durability of textile-reinforced composite materials are provided. The textile reinforcement may be knitted, for example, in a flat bed weft knitting machine. The method may include pre-stressing a textile reinforcement preform by applying tension. A polymeric precursor may be introduced to the pre-stressed textile reinforcement preform. The polymeric precursor may then be cured or consolidated, followed by releasing of the applied tension to form the composite article comprising polymer and the pre-stressed textile reinforcement. In other aspects, a composite article is provided that has a pre-stressed textile reinforcement structure and a cured polymer. The textile reinforcement may be a knitted, lightweight, seamless, unitary structure. The knitted reinforcement structure may have distinct first and second knitted regions with different levels of pre-stress, thus providing enhanced control over strength, rigidity, and flexibility of the composite article.